CHASSIS DYNAMOMETER Maintenance & Service … Chassis Dynamometer Maintenance & Service Manual WARNING Unsafe operating practices can lead to potentially dangerous situations when

MD-100-M-HD SERIES

C H A S S I S D Y N A M O M E T E R

Maintenance & Service Manual

MD-100-M-HD Chassis DynamometerMaintenance & Service Manual

MD-100 Chassis Dynamometer

Information in this document is subject to change without notice. Nopart of this document may be reproduced or transmitted in any formor by any means, electrical or mechanical, for any purpose, withoutthe express written permission of Mustang Dynamometer.

Copyright © 2002Ganzcorp Investments, Inc. dba Mustang Dynamometer

All rights reserved

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NOTICEThis manual has been designed and written to provide usefulinformation about Mustang Dynamometer equipment and systems.Every effort has been made to make this manual as complete andaccurate as possible, but no warranty or fitness is implied.

The information contained in this manual is provided on an "as is"basis. Neither the author of this manual nor the management andowners of Mustang Dynamometer shall have either liability orresponsibility to any person or entity with respect to any loss ordamages arising from the information contained in this manual.

2300 Pinnacle ParkwayTwinsburg, Ohio 44087 USA

Ph: (330) 963-5400Fax (330) 425-3310

www.mustangdyne.com


WARNINGUnsafe operating practices can lead to potentially dangeroussituations when your machine is running.

Only properly trained and responsible personnel shouldattempt to operate this machine.

WARNINGDo not operate or perform any maintenance on yourequipment until you have carefully read this manual in itsentirety making sure that you understand all of the materialpresented in each section.

WARNINGRemoval and disassembly instructions in this manual have beenreduced to a minimum for ease of readability.

Only experienced maintenance personnel should attempt toinstall and/or make repairs to this machine.

WARNINGKeep limbs, hair, jewelry and clothing away from themoving rolls. When operating a vehicle on the machine,remain inside vehicle until the rolls have stopped. Cover therolls when the equipment is not in use.

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WARRANTYLIMIT OF LIABILITY

Mustang warrants that the product(s) that is the subject of this sale is free from defects in material. Theduration of this warranty is one year from date of shipment on all Mustang-related components.Components not manufactured by Mustang will carry the original manufacturer's warranty, typically 90days for all electronic-related components. All warranty claims must be processed through Mustang.

If a problem arises within the applicable warranty period, it is the responsibility of the purchaser to (a)promptly notify Mustang in writing (b) obtain a RMA Number from Mustang (c) return to Mustang thecomponent(s) that are claimed to be defective (transportation charges must be prepaid by the purchaser).RMA Number must be clearly marked on outside of package(s).

Within a reasonable time after such notification, Mustang will correct any defect(s) in component(s). IfMustang is unable to repair the component after a reasonable number of attempts, or if Mustangdetermines at any time the repair is impracticable, Mustang will provide a replacement with like orsimilar component(s). The purchaser is responsible for all transportation expenses to and from Mustangand all labor expenses associated with removal and replacement of the component(s) as well as laborinvolved to repair component(s). Mustang will bear the expense of parts only. These remedies are thePurchaser's sole remedies for breach of warranty.

The expiration of the warranty period, use of the product for purposes other than those for which it isdesigned, other abuse or misuse, unauthorized attachments, modifications, or disassembly, ormishandling of the product during shipping, shall end all liability of Mustang.

In no case shall Mustang be liable for any special, incidental, or consequential damages based uponbreach of warranty, breach of contract, negligence, strict tort, or any other legal theory. Such damagesinclude but are not limited to, loss of profits, loss of savings or revenue, loss of use of the product or anyassociated equipment, cost of capital, cost of any substitute equipment, facilities or services, downtime,the claims of third parties including customers, and injury to property.

Unless modified in writing and signed by officers of both parties, this agreement is understood to be thecomplete and exclusive agreement between the parties, superseding all prior agreements, oral or writtenand all other communications between the parties relating to the subject matter of the agreement.

GANZCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER

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CONTENTS

1.1 What Is A Chassis Dynamometer 1-2

1.2 About This Manual 1-3

1.3 Important Message Boxes 1-4

1.4 Before You Start 1-5

1.5 If You Need Help 1-5

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Introduction Section1

1.1 What is a Chassis DynamometerToday and in the future, automobiles and trucks will be required to meet increasinglystringent emissions and safety standards. In many cases, dynamic testing - either on-highway or with a chassis dynamometer - is the only way to adequately measure vehicleperformance or emissions.

A Mustang Chassis Dynamometer (sometimes referred to as a "Dyne" or "Dyno") is arugged piece of equipment which is used to apply a load to a test vehicle. The MustangChassis Dyne is an integrated assembly of mechanical, electro-mechanical, and electri-cal/electronic sub-systems which function together to provide you with the ability tosimulate actual road loads while the vehicle being tested remains in the safe and con-trolled confines of a test center. In addition to the vehicle performance informationprovided by the Dynamometer System during a test, this capability will, if so desired, alsoenable you to connect test instruments and diagnostic equipment to the test vehicle'sengine to monitor specific engine performance characteristics.

As the torque from the test vehicle's drive wheels causes the rolls of the Dyne to rotate,Mustang's air-cooled electrical eddy current Power Absorbing Unit (PAU) opposes thisforce by converting the vehicle's kinetic energy into heat. A microcomputer-based controlunit, using closed-loop feedback control, regulates the amount of power that is absorbedby the PAU and, as a result, the amount of load that is imposed on the test vehicle.

The Chassis Dynamometer has emerged as a major asset in the areas of EmissionsTesting, Fault Diagnosis, Performance Engineering, and Test Engineering throughout theworld. Chassis Dynamometers can be used to perform a wide variety of tests on cars,trucks, and tractors; some examples of these tests deal with …

� Vehicle Heating & Cooling Systems

� Engine Performance

� Drive Train Component Evaluation

� Transmission Components

� Tire Testing

� Road Grade Simulation

� Trailer Towing Simulation

� Fuel Efficiency

� Auxiliary Components

� Failure Analysis

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Introduction


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1.2 About This ManualThis manual provides you with the information you will need to know when you want toinstall and perform routine maintenance as well as more complex service on yourMustang Chassis Dynamometer. The following sections are included in this manual:

Section 1 - Introduction This is the section you are currently reading.

Section 2 - The System This section presents a description of theChassis Dynamometer System to familiarize youwith its major components. In addition, theprinciples of dynamometer operation arediscussed.

Section 3 - Safety First A number of very important safety tips arepresented in this section. BE SURE TO STUDYTHIS SECTION CAREFULLY!

Section 4 - Installation A step-by-step procedure is given in this sectionto help ensure that your Dyne is installedproperly.

Section 5 - Controls & Calibration Information pertaining to the control box andwiring, and calibration instructions.

Section 6 - Operational Checkout A sequence of operational checks is provided inthis section to verify that your system isoperating properly.

Section 7 - Preventative Maintenance General maintenance and lubrication instructionsare presented in this section.

Section 8 - Troubleshooting Some basic troubleshooting hints are containedin this section.

Appendices The appendices contain reference informationthat you can easily access when you need it.

MD-100 Chassis Dynamometer - Introduction

Introduction


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1.3 Important Message BoxesWhen you read this manual and operate and maintain your MustangDynamometer System …

Be sure to observe all DANGER, WARNING, and CAUTION advisories!

These advisories point out potentially hazardous procedures and conditions. Ascan be seen below, all three types of advisories are enclosed in a box to callattention to them.

This is an example of a DANGER message. A DANGERmessage alerts a person that severe bodily injury or loss of lifecould occur if procedures are not followed.

DANGER

This is an example of a WARNING message. A WARNINGmessage alerts a person to potential bodily injury if proceduresare not followed.

DANGER

WARNING

This is an example of an electrical DANGER message. Anelectrical DANGER message alerts a person that, as a result ofelectrical shock, severe bodily injury or loss of life could occur ifprocedures are not followed.

This is an example of a CAUTION message. A CAUTIONmessage alerts a person that if procedures are not followed,damage to, or destruction of the equipment could result.

CAUTION

This is a example of a NOTE box. A NOTE box is generally usedto bring to your attention information that should be of particularbenefit, information that pertains to a special situation, etc.

NOTE

MD-100 Chassis Dynamometer - Introduction

Introduction

1.4 Before You StartBefore attempting to operate your Mustang Chassis Dynamometer for normal usage, it isvery important that…

� Your Dynamometer has been properly installed.

� Your Dynamometer has been properly maintained.

� Your Dynamometer has been properly calibrated.

� No unsafe conditions exist with your Dynamometer or your work site.

� All personnel who will be performing maintenance and service on yourDynamometer have read this manual in its entirety and understand all of theinformation presented.

1.5 If You Need HelpMuch effort has been extended to make this manual easy to work with as well ascomplete and accurate. However, if there is something that you do not understand orsomething that you have a question about, please feel free to contact a Mustangrepresentative at …

MUSTANG DYNAMOMETER2300 Pinnacle Parkway

Twinsburg, Ohio 44087 USAPhone: (330) 963-5400

Fax: (330) 425-3310E-mail: [email protected]

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Introduction

CONTENTS

2.1 Introduction 2-2

2.2 Major System Components 2-2

2.2.1 Dynamometer 2-3

2.2.2 Control & Monitoring System 2-4

2.3 Principles Of Operation 2-6

LIST OF FIGURES

Fig. 2.1 Major Components of the Dynamometer Sub-system 2-3

Fig. 2.2 Major Components of the Control & Monitoring Sub-system (Part 1 of 2) 2-4

Fig. 2.3 Major Components of the Control & Monitoring Sub-system (Part 2 of 2) 2-5

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SectionSection The System2


2.1 IntroductionThis section of the manual provides general information that will help you to develop acomprehensive understanding of your Mustang Chassis Dynamometer System. Thefollowing topics are covered in this section:

� Major System Components

� Principles of Operation

When learning to operate and/or maintain your new Mustang Chassis Dynamometer westrongly suggest that you take a few moments to familiarize yourself with the informationpresented in this section of the manual. Doing so will greatly help you to understand theinformation that is presented in other sections of this manual.

2.2 Major System ComponentsThe major components of a Mustang Chassis Dynamometer System can be grouped intothe following categories which are discussed below:

� Dynamometer

� Control & Monitoring System

2.2.1 Dynamometer

The Dynamometer Sub-system is defined here as being comprised of primarilythose system components that are "mechanical" or "structural" in nature. Thesecomponents are illustrated and discussed on the following pages (see Fig. 2.1).

2-2

MD-100 Chassis Dynamometer - The System

The System


2-3

KEY (Fig. 2.1)

1… Frame Double welded heavy structural steel frame.

2… Inertia Weight Dynamically balanced inertia weight provides additionalloading capability.

3… Pillow Block Ball bearings are mounted in a gray iron pillow blockBearings housing for exceptional strength. Bearings can float to

minimize misalignment of shafts.

4… Rolls The dyne is equipped with a Drive Roll set and an IdlerRoll set. All rolls are dynamically balanced for speeds upto 125 MPH. The surfaces of the rolls are grooved toprovide maximum traction and good tracking.

5… Toothed Belt Rugged toothed drive belt used to couple front and rearrolls together.

6… Coupling High power couplings are used to accurately transmitspeed and power to instrumentation.

7… Brake System The pneumatic lift system (with integrated roll locks)provides for easy vehicle entry to and exit from the Dyne.

8… Restraints Provides an additional degree of safety during testing.


FIG. 2.1MAJOR COMPONENTSOF THE DYNAMOMETERSUB-SYSTEM

The System


2.2.2 Control & Monitoring System

The Control & Monitoring Sub-system is defined here as being comprised ofthose electrical, electro-mechanical, and electronic system components that areprimarily used to control the operation of the system and to monitor the behaviorof the vehicle during a test. Only those Control & Monitoring Sub-systemcomponents that are mounted on the dynamometer are considered in thissection; these components are illustrated and discussed below (see Fig. 2.2).

NOTE: Your configuration may have differences from the figure shown. Forexample, the PAU may be on the left side of the roll set, etc.

KEY (Fig. 2.2)

1… Power Absorber An eddy current Power Absorbing Unit (PAU)Unit (PAU) provides infinitely variable loading without the

use of water or hydraulics. The PAU can operatewhile rotating in either direction. Its ruggedconstruction enables it to be operated underextremely demanding conditions. The PAU iswired for 96 VDC operation.

2… PAU Load Cell The strain gauge load cell, excited with 10 VDC,produces a DC output signal as it is eithercompressed or expanded. The rated accuracyof the Load Cell is ± 0.1%.

3... Warm-up Motor A 5 HP motor is integrated into the system toperform automated warm-up andcoastdown procedures.

FIG. 2.2MAJOR COMPONENTSOF THE CONTROL &MONITORING SUB-SYSTEM (part 1 of 2)

2-4


The System


2-5

FIG. 2.3MAJOR COMPONENTSOF THE CONTROL &MONITORING SUB-SYSTEM (part 2 of 2)

KEY (Fig. 2.3)

1… DAQ I/O Board This board provides an interface to thedynamometer for the Control Box.

2… DAQ Board The DAQ board is the brains of the controlsystem. The dynamometer controlmicroprocessor is located on this board.

3… PAU Isolation Board The PAU Control Board uses a 0-5 VDC inputsignal from the DAQ board to produce a 0-96VDC output that is furnished to the PAU.

4… Power Supply Provides DC power to the DAQ and DAQ I/Oboards.

5... Motor Controller The drive system for the 5 HP warm-up motor.


4… Air Lift Solenoid This valve controls the flow of pressurized air(maximum valve of 80 PSI) to the lift air bagsenabling them to quickly inflate and deflate.

5… Mag Pickup One revolution of the drive line will cause 60pulses to be generated. By measuring the timebetween pulses generated, the speed of rotationcan be calculated.

The System

2.3 Principles of OperationYour MD-100 Chassis Dynamometer will give you the ability to simulate actualroad loads while the vehicle is stationery. This enables you to perform tests on avehicle while test diagnostic instruments are connected to the vehicle's engineand exhaust system.

The Dynamometer consists primarily of drive roll set, an idler roll set, a powerabsorbing unit (PAU), a load cell, and a speed encoder. The drive roll set andidler roll set are coupled together by a toothed drive belt with the optional bi-directional package. This enables the test vehicle to face in either direction whenit is on the dyne and being tested.

During operation of the Dyne, the vehicle's drive wheels are cradled between thedrive rolls and the idler rolls. The vehicle's torque is transmitted through the driverolls to the eddy-current Power Absorbing Unit (PAU). The PAU is trunnionmounted directly in the dyne's drive line. It is prevented from "freely" rotating bythe installation of a load cell. The "load" is measured by the load cell and istransmitted to the control system via an electrical signal. The PAU absorbs thisload by energizing stationary electric field coils with a direct current. These coilsestablish magnetic fields through which the iron rotors of the PAU are rotated.This rotation generates eddy-currents in the rotors which produce a force that iscounter to the direction of the rotary motion. The power absorbed by the PAU isdependent upon the amount of DC power applied to the field coils and the RPM ofthe spinning rotors. The speed of rotation of the rotors is measured by amagnetic device called a mag pickup and is transmitted to the control system.

When both torque (from the load cell signal) and speed (from the mag pickupsignal) are known, horsepower can easily be determined.

2-6 The System


CONTENTS


3.2 General Safety Issues 3-3

3.3 Operational Safety Issues 3-4

3.4 Maintenance Safety Issues 3-5

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Section Safety First3


3.1 Introduction

Attention!Dynamometer operation is potentially dangerous. For your ownsafety, read and understand the following warnings beforeconducting any tests. If you cannot read English, or havedifficulty understanding these warnings, please ask a super-visor or co-worker to explain them to you.

¡Atención!La operación dinamómetra es bastante peligrosa. Para suseguridad, lea detenidamente las siguientes advertencias antesde efectuar las pruebas. Si usted no lee inglés o si tienedificultad con la interpretación de estas advertencias, por favorpídale a su supervisor que le interprete las direcciones.

DANGER

This equipment contains voltages which may be hazardous ifcontacted. Avoid contacting terminals, binding posts, and otherexposed connections.

DANGER

Throughout this manual you will encounter DANGER, WARNING, and CAUTIONmessages. These messages are intended to alert you to situations that arepotentially dangerous to you or damaging to your machine. Please pay attentionto these advisories and follow the directions given in them.

The safety messages presented below are categorized as follows:� General Safety Issues� Operational Safety Issues� Maintenance Safety Issues

The General Safety Issues apply whenever you are working with the dyne for anyreason. The Operational Safety Issues alert you to hazards that may arise duringthe operation of the dynamometer whether it is being operated for vehicle testingor during an operational checkout. The Maintenance Safety Issues alert you tohazards that may arise when you are performing maintenance and service onyour dynamometer system. Please be sure to read and follow the directives in allof the safety messages given in this section.

3-2

MD-100 Chassis Dynamometer - Safety First

Safety First


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3.2 General Safety IssuesBe Knowledgeable … Do not attempt to operate, maintain or service our MustangChassis Dynamometer System until you have familiarized yourself with the equipment byreading the instructions in this manual.

Prepare Correctly … To avoid possible injury to personnel or damage to equipment donot apply power to your Mustang Chassis Dynamometer System until the followingprocedures have been satisfactorily completed:

� Installation (Section 4)� Controls & Calibration (Section 5)� Operational Checkout (Section 6)

Act Responsibly … Exercise caution and discretion when operating or performingmaintenance on your dyne. Always observe typical, common sense test areaprecautions.

Beware of Projectiles … Tires that are rotating at high rates of speed can throw offstones and other projectiles. Wear approved safety glasses when in the vicinity of thevehicle being tested.

Protect Your Ears … Dynamometer noise can damage your hearing. Always wearapproved ear protection when working near the dynamometer.

Beware of Being Grabbed … Keep limbs, hair, jewelry, and clothing away from themoving dynamometer rolls, belt, couplings, etc.

Cover Rolls … The rolls can move freely whenever the roll brake is not applied. Neverwalk on the rolls. Cover the rolls when the dynamometer is not in use.

Pay Attention … Maintain acute awareness when the dynamometer rolls are in motion.


Safety First


3-4

3.3 Operational Safety Issues

Vent Engine Exhaust … Provide adequate room ventilation. High concentrations ofengine exhaust can be deadly. Do not operate your Dynamometer without properventilation. The shop ventilation system should exchange 300 to 500 cubic feet of air perminute (500 cfm preferred).

Monitor Carbon Monoxide … Make sure you have installed a carbon monoxide monitorin the dynamometer bay.

Guarding … Provide floor markings and protective guard railings for customer/operatorprotection. NEVER operate your Dyne with any of its cover panels removed unlessspecifically directed to do so elsewhere in this manual.

Refresh Your Knowledge … Regularly review the operating procedures presented inthis manual.

Keep Clear of Rolls … Stay away from the rolls when in operation.

Protect Eyes and Ears … Make sure that you wear proper eye and ear protection whenoperating the dyne.

Check Tires … Before driving the test vehicle onto the dyne, be sure to check thevehicle's tires for proper inflation. Inspect the tires for any signs of damage and removeany large embedded objects from the tread.

Restrain Vehicle Movement … During dynamometer operation it is common for the testvehicle to move laterally on the rolls. Also, unrestrained vehicles can launch off the dyne,causing death or serious injury.

To prevent personal injury and/or damage to the test vehicle, it is imper-ative that, prior totesting the vehicle, you secure the test vehicle in all directions (front, rear, and sides) withapproved safety restraints that are bound to properly installed floor anchor pods.

Wheel Chocks … Use wheel chocks for the vehicle that is under test. Install one inch infront of non-driven wheels of test vehicle.

Proper Clearance … Always ensure that there is a clearance of at least four (4) feet tothe front, rear, and sides of the dynamometer.

Stay Seated … The vehicle operator MUST remain in the driver's seat at all times duringa drive-cycle test. Do NOT attempt to get in or out of the vehicle while the dynamometerrolls are moving.

If in Doubt, STOP! … Stop the equipment immediately if you have any doubt about thesafe operating condition of the dynamometer and/or the correctness of any procedure thatyou are performing.


Safety First


3-5

3.4 Maintenance Safety IssuesElectrical Shock Hazard … Turn off electrical service to the system before performingany maintenance activity. Turn off the main breaker in your breaker box before workingon anything related to the PAU.

No Jewelry … Before performing any electrical or mechanical trouble-shooting, repair,etc. on the dyne, it is highly advisable to remove any jewelry that you may be wearing..

Dyne Cover Panels … Use extreme caution around drive mechanisms and moving partswhen operating the dyne with any of its cover panels removed from the chassisassembly.

Avoid Straining Yourself … Be careful when lifting dyne cover panels - they are veryheavy. Be very careful when replacing belts, couplings, or bearings - the rolls are veryheavy and can be difficult to handle.

Air Pressure … Make sure that there is no air pressure in the lines whenever you areworking on the lift plates or air bags.

Watch Your Hands … Never put your hand between the lift plate and roll when there isair hooked up to the system.

NEVER, NEVER, NEVER! … Never pull on the drive belt in order to spin the rolls.

Check Tightness … Make sure that all bolts on the Dyne are tight and all couplings areproperly secured.


Safety First

CONTENTS


4.1 Inspection 4-2

4.2 Tools & Equipment Needed For Installation 4-2

4.3 Shop Layout & Requirements 4-3

4.3.1 Pit Excavation (below-ground installation only) 4-34.3.2 Electrical 4-34.3.3 Pneumatic (Air) 4-34.3.4 Ventilation 4-34.3.5 Chain Anchors 4-44.3.6 Clearance 4-4

4.4 Above Ground Installation 4-4

4.5 Below Ground Installation 4-6

4.7 Pre-operational Inspection 4-12

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Installation Section4

4-2

4.0 IntroductionThis section of the manual provides detailed instructions that you should follow wheninstalling your new Mustang Chassis Dynamometer.

These instructions cover the installation of all Mustang models (i.e., standard & heavy-duty, uni- and bi-directional). Both in-ground and above-ground installations are coveredas well as various methods of securing the dyne to the floor (ex. weld plates, studanchors, anchor bolts).

4.1 Inspection

After unloading the dynamometer from the delivery truck and prior to the departure of thetruck driver a visual inspection must be made of the dynamometer. If there is anyapparent damage to the shipping crates it must be noted on the bill of lading prior toaccepting delivery of the dynamometer. After uncrating the equipment check the contentsof the crates with the enclosed packing list. The following is a list of items that shouldhave been received. Notify MUSTANG DYNAMOMETER immediately if you find anyshortages or damage with this shipment.

1. Dynamometer2. Dyne control box3. Control box to dyne cable4. Load cell5. Speed encoder (mounted on dynamometer)

4.2 Tools & Equipment Needed for Installation

1. Shim stock (can be purchased separately from MD)2. 1/2" Eyebolts (4), to lift dynamometer (can be purchased separately from MD)3. Chains with hooks (2)4. 5/8" Masonry drill bit5. Hammer drill6. Forklift, minimum 3 ton capacity7. Standard hand tools


Installation


4.3 Shop Layout & RequirementsThis section includes minimum requirements necessary to install the Dynamometer and toensure safe operation. After determining which method of installation is best for you it isnecessary to adhere to the following conditions.

4.3.1 Pit Excavation (Below-Ground Installation Only)

A below ground installation requires a floor opening of very specific dimensions. Adrawing has been provided with your dynamometer depicting proper pit dimensions. It isrecommended that you contract the services of a licensed contractor to perform theexcavating of the dynamometer pit.

4.3.2 Electrical

Your local electrical codes will determine how these circuits should be wired.

4.3.3 Pneumatic (Air)

The Dynamometer requires an air supply line to operate the lift and brake systems. Theairline should supply at least 80 psi but not more than 120 psi. An air dryer and regulatorshould be installed in the main supply line with the regulator set for 80 psi.

4.3.4 Ventilation

Your shop should be equipped with an effective ventilation system to direct tailpipeemissions to the outside air. Exhaust vents should be able to connect to all type ofvehicles (front-wheel drive, rear wheel drive, dual exhaust, etc.)

4-3

MD-100 Chassis Dynamometer - Installation

The installer of the dynamometer accepts full responsibility foradhering to local, state and federal construction codes. Thefactory will not be held liable for damage or injury caused byimproper installation.

WARNING

MD-100-M-HD 115 VAC single phase, 60 Hz, 30 Amps

Dynamometer Electrical Service

Installation


4-4

4.3.5 CHAIN ANCHORS

It is common for vehicles to move laterally on the rollers during dynamometer operation.To prevent personal injury and damage to the vehicle it is imperative that the vehicle besecured with chains using 4 chain anchors that should be permanently installed asillustrated in the Appendix.

4.3.6 CLEARANCE

It is important to have enough room around the dynamometer to allow equipment to bemoved around the service bay area. At least 20 feet clearance is needed in front of thedynamometer so that the vehicle under test has enough room to pull in the service bay.

There are two ways to install a Mustang Chassis Dynamometer, above ground or belowground. The following section describes both methods.

4.4 Above-Ground Installation

NOTE: Your configuration may have differences from the figure shown. Forexample, the PAU may be on the left side of the roll set, etc.

If using this type of installation the dyne will be anchored to the shop floor using "thunderstuds". Since the top surface of the dyne will be off of the ground, optional ramps areneeded to drive the front or the rear of the car to the rolls.


Installation


4-5

Advantages � Least expensive type of installation � An existing shop requires little renovation � Easy to move dynamometer

Disadvantages � Dynamometer takes up floor space � Not recommended for high speed testing

4.4.1 Above-Ground Installation Procedure

1. Remove P.A.U. cover, center cover and the bearing cover (end opposite the PAUcover) from the dynamometer. Screw the 4 eyebolts into the holes along the mainframe. Secure the chain to the eyebolts.

2. Lift the dynamometer by the chain and locate it in an appropriate location, keep inmind the clearance requirements discussed in the previous section.

3. Remove the lift plate opposite the retarder.

4. In the 7 anchor locations, drill 5/8" diameter holes 6" deep into the concrete.Ensure the holes are clear of dust and debris.

5. With the dynamometer in position, level the dynamometer using steel shim stock.If the dynamometer needs shims, place them underneath the dynamometerframe near the 7 anchor locations.

6. With the nut of the "Thunderstud" flush with the top of the stud, tap the"Thunderstuds" into the holes until the washer is flush with the dynamometerframe.

7. Expand the anchors by tightening the nut.

8. Re-install lift plates, torque bolts to 35 ft-lbs.


Installation


4-6

4.5 Below-Ground Installation

NOTE: Your configuration may have differences from the figure shown. For ex-ample, the PAU may be on the left side of the roll set, etc.

The Dynamometer is lowered into a pit, allowing the rollers to be flush with the floorsurface.

Advantages � The bulk of the dynamometer is below ground � Vehicles are level with the ground � Easy to drive vehicle on & off of dynamometer

Disadvantages � More expensive installation costs � Requires renovation to existing shop � Dynamometer cannot be easily moved


Installation


4-7

4.5.1 Below-Ground Installation Procedure

1. Check dynamometer pit and verify dimensions. Also, make sure the conduits arein the proper locations.

2. Clear the pit of all debris.

3. Remove cover plates from the dynamometer. Screw the 4 eyebolts into the holesalong the main frame. Secure the chain to the eyebolts.

4. Lift the dynamometer evenly with the chain and lower it into the pit. There shouldbe approximately 1/2" clearance between the frame and all walls of the pit.

5. Remove the lift plate opposite the retarder.

6. In the 7 anchor locations, drill 5/8" diameter holes 6" deep into the concrete.Ensure the holes are clear of dust and debris.

7. With the dynamometer in position, level the dynamometer using steel shim stock.If the dynamometer needs shims, place them underneath the dynamometerframe near the 7 anchor locations.

8. With the nut of the "Thunderstud" flush with the top of the stud, tap the"Thunderstuds" into the holes until the washer is flush with the dynamometerframe.

9. Expand the anchors by tightening the nut.

10. Re-install the lift plates, torque bolts to 35 ft-lbs.


Installation


4-8


Installation

4.6 Pre-Operational Inspection

WARNING: These procedures take at a minimum of 2 qualified personnel.

DO NOT PLUG THE SYSTEM INTO THE POWER SUPPLY.DO NOT TURN ON SYSTEM OR HAVE A VEHICLE ON DYNAMOMETER.

1. Verify the installation of the dynamometer meets all guidelines outlined in thismanual. Do this NOW by reviewing the step by step installation procedures.

2. Verify the proper installation of the chain anchors.

3. Verify and check the torque of all the bolts and set screws to the specificationslocated in the Appendix. This procedure is very critical as some components mayhave loosened during shipping.

4. Verify all cable and air line connections are properly fastened, secured, andtightened.

5. Rotate dynamometer rollers by hand or foot ( a car should not be on at this time )and verify they spin freely. The rollers will be somewhat difficult to spin due to thelarge mass that rotates.

6. Check to see that there is plenty of clearance around the rollers and that nocomponents are rubbing, or are near rubbing.

7. Check all cabling and air lines to be sure that they are secured and clearly awayfrom any rotating components.

8. Check the leveling of the dynamometer and ensure it is secured to the floor.

9. Clean up all installation tools in and around the dynamometer frame.


MD-ASM-97-XX-HD Chassis DynamometerMaintenance & Service Manual

CONTENTS


5.2 Controls Installation 5-2

5.3 Setup 5-4

5.4 Calibration 5-6

5.5 Controls Troubleshooting 5-9

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Section Controls & Calibration5


5-2


Controls & Calibration

5.2 Controls Installation

The dynamometer control system consists of a drive control box, computer system(customer supplied), and associated cables ( refer to Fig. 5.1 ). If the dynamometer is notto be installed in a pit, wire covering should be used to protect cabling and air lines.

FIG. 5.1CONTROL SYSTEMINTERCONNECTDIAGRAM

5.1 IntroductionThis section contains information on how to install, setup, calibrate, test, and troubleshootthe MD-100-M-HD dynamometer controls. Refer to the Preventive Maintenance section of thismanual for specific procedures required for dynamometer setup, calibration, and testing.

WARNINGThis equipment contains voltages which may be hazardousif contacted, Avoid contacting terminals, binding posts, andother exposed connections. Failure to observe these precau-tions may result in damage to equipment, injury to person-nel, or both.


5-3

5.2.1 Control System Installation Procedure

1. Take the "dummy" load cell out by removing the large bolts from the upper andlower load cell brackets. Attach the load cell on the lower bracket first. Uponcompletion, attach the load cell to the upper bracket. Tighten both bolts to 50 ft-lbs. Torque the eyelet bolt jam nuts to 200 in-lbs. DO NOT OVERTIGHTEN !

NOTE: Position the load cell so the wire is on the side opposite the Power Absorbing Unit.

2. Route cabling and air line. Leave enough slack in the cables and the air line sothat the appropriate connection can be made.

3. After routing the air line, push the plastic air line into the quick release air fitting onthe air solenoid until it is snug. Make sure that the air line will not come intocontact with the rolls.

4. Install main air supply line to the tubing near the conduit run to the dyne. This airsupply must have an in line air dryer and must be regulated between 80- 120 psi.

5. Connect the 3 pin male CPC connector to the 3 pin female CPC connector on thecontrol box labelled “To PAU”.

6. Connect the 7 pin male CPC connector to the 7 pin female connector on thecontrol box labelled “To Motor”.

7. Connect the 37 pin male CPC connector to the 37 pin female connector on thecontrol box labelled “To Dynamometer”.

8. Connect customer supplied 7 pin female CPC connector to the 7 pin female CPCconnector on the control box labelled “Serial Communication”.

9. Install main power input to the Drive Control Box as shown in Fig. 5.1. This circuitshould come from the facility main supply box and must be a FUSABLE DISCON-NECT. Power requirements are listed in Section 4.3.2 - Electrical.

Note: It is the customer's responsibility to ensure this circuit is installed accordingto all applicable building codes.


Controls & Calibration


5.3 Setup5.3.1 Inspect Dynamometer

Make sure the dynamometer is secured to the floor and all bolts are properly tightened.

Check belt tensions.

Check speed sensor air gaps.

Check the load cell(s) for tightness.

5.3.2 Check ConnectionsMake sure all cables are connected.

Verify that the 230 Vac (208 Vac minimum) connection to the control box has a 30 Ampfuse or circuit breaker.

Verify that the air pressure is regulated to 60 to 80 psi and that there are no air leaks.

Make sure restraints are installed.

Check the control box and make sure the E-stop button is pulled out, the lift overrideswitch is off, and the lift solenoid override screw is horizontal.

5.3.3 Install JumpersInstall jumper on J5, pins 2 and 3 on the I/O PCB (Speed Encoder Excitation).

Make sure jumpers J16,J17 and J18 are installed.

Refer to Figure 5.2 and make sure the following jumpers are installed on the DAQ PCB:

Initialization Jumpers EPROM Socket Setup Span Output Jumpers

01 J2-1 noitisoP 1J0 D11 J2-1 noitisoP 2J8 D

J3 Position 1-2 J 12J 13J 14J 15

All other jumpers should be empty. Note: J 19 is used for factory testing and must beremoved.

5.3.4 Boot SystemTurn on the customer supplied control PC and the 230 Vac supply. When the computerhas started, the DAQ Board should read: MONITR .

Verify that all ten (10) LED’s on the DAQ Board are lit. If the center “READY ” lamp is offmake sure the lift is down, 230 Vac is present, the motor is not turning, and the E-stopswitch is out. If the “READY ” light is still not lit, the motor may have a fault, refer to theTroubleshooting portion of this section.

5-4 Controls & Calibration


5-5Controls & Calibration

FIG. 5.2DAC BOARD LAYOUT


5.4 Calibration

Calibration consists of calibrating the Load Cell and the KB board and setting torque,command and analog input voltage levels. Calibration is performed using the keyboard anddisplay on the DAQ printed circuit board located in the control box. Refer to Figure 5.2 foran illustration of the DAQ printed circuit board and the Appendices for the DAQ PC FlowChart.

Five pushbuttons are used to navigate through a series of functions that control thedynamometer. Calibration sequences are listed in tables that describe each keypress, thedisplay output, and the function or action to be performed. Display output values areexamples only.

5.4.1 Calibrate PAU Load Cell

5.4.1.1 Program Calibration Arm Length and Calibration Weight

To program the calibration arm length and calibration weight value, follow the steps listedbelow.

Select Display Function/ActionMONITR Start

�� CALVAL Dynamometer setupENTER RL DIA�� CL ARmENTER 24.00 Current arm lengthEXIT CL ARm�� CAL WEIGHTENTER 49.219 Current calibration weight setting

49.219 To change the setting:�� 49.219 Use keys to set new weightENTER DONEEXIT OK SAV Save the new settingEXIT CALVAL

5.4.1.2 Zero Load Cell (Initial)

To zero the load cell, follow the steps listed below.

Select Display Function/Action�� CALPRCENTER ZR LC1 Zero Load Cell

Attach calibration arm. Make sure lift is down androlls are not moving.

ENTER DONE Will flash then go back to ZR LC1If ERROR Flashes, then you do not have a goodZero.



5.4.1.3 Span Load Cell

To span the load cell, follow the steps listed below.

Select Display Function/Action�� SP LC1 Put cal weight on load cell side of cal arm. Ensure

lift is down and rolls are not movingENTER Done Will flash then go back to SP LC1EXIT OK SAV Save the new settingEXIT CALPRC

If ERROR flashes, then you do not have a gooda good Span.

5.4.1.4 Zero Load Cell (Final)

To zero the load cell, follow the steps listed below.

Select Display Function/Action�� CALPRCENTER ZR LC1 Zero Load Cell

Remove calibration arm. Make sure lift is downand rolls are not moving.

ENTER DONE Will flash then go back to ZR LC1If ERROR flashes, then you do not have a goodZero.

5.4.2 Calibrate KB BoardKB Board calibration adjusts the PAU zero and span voltages.

Before applying voltage to the system, refer to Figure 5.3 and make sure thepotentiometers on the KB board are set correctly.

To calibrate the KB board, use the pushbuttons and display on the DAQ printed circuitboard as follows:

Select Display Function/ActionMONITR Start

�� CALPRCENTER ZR LC1�� ZR KB1ENTER Z1 NOW Slowly adjust MIN potentiometer until voltage

starts to rise, then slowly adjust MIN for 0 Vdcbetween A+ and A- on KB board. See Figure 5.3.

EXIT ZR KB1�� HSPKB1ENTER HS1NOW Sending Span reference voltage to PC and KB.

Adjust IR potentiometer for 30 Vdc between A+and A-. See Figure 5.3.

EXIT HSPKB1�� FSNKB1 DO NOT USE THIS. This will give full span to the

PAU



FIG. 5.3KB BOARD LAYOUT



5.5 Controls Troubleshooting

The following procedures and tables are provided in an effort to aid in resolvingoperational, testing, and failure problems with the dynamometer control system. Theinformation provided in this section is presented as a guide to troubleshooting the MD-100-H-HD dynamometer system.

WARNINGThis equipment contains voltages which may be hazardousif contacted, Avoid contacting terminals, binding posts, andother exposed connections. Failure to observe these precau-tions may result in damage to equipment, injury to person-nel, or both.

5.5.1 No Torque Reading on Base Unita) Make sure all cables are connected.

b) Open the control box, and using the DAQ board, follow the flow chart to Monitor,then press Enter, then scroll down to PAUTRQ. Press on the load cell and lookfor a change in the displayed value.

c) If this reading does change, skip ahead to step f). If this reading does not change,go to step d).

d) Go to connector J4 on the I/O board and monitor the voltage across pins 7 (sig+)and 8 (sig-), look for a change in response to pressure on the load cell.

e) If this voltage changes in response to pressure go to step g). If not go to step f).

f) Replace the 50-pin ribbon cable between the DAQ-PC and the I/O board; if thisdoes not fix the problem replace the DAQ-PC.

g) Measure the voltage across pins 4 (exc-) and 3 (exc+); you should read 5 Vdc.

h) If this voltage is present check the load cell connections on the dyne cable and/orreplace the load cell.

i) If this voltage is not present, replace the I/O board.



5.5.2 Not seeing speed on the base unita) Make sure all cables are connected.

b) Open the control box, and using the DAQ board, follow the flow chart to Monitor,then press Enter. Manually spin the rolls and look for a change in the displayedvalue.

c) If this reading does change, skip ahead to step f). If this reading does not change,go to step d).

d) Go to connector J4 on the I/O board and monitor the voltage across pins 13 (2.5vdc +/- 0.5 vdc) and 15 (GND), look for this voltage level while the rolls arespinning.

e) If this voltage changes go to step g). If not go to step f).

f) Replace the 50-pin ribbon cable between the DAQ-PC and the I/O board; if thisdoes not fix the problem replace the DAQ-PC.

g) Measure the voltage across pins 12 (+5 vdc) and 15 (GND); you should read 5vdc (excitation for speed sensor).

h) If this voltage is present check the speed sensor connections on the dyne cableand/or replace the speed sensor.

i) If this voltage is not present, replace the I/O board.

5.5.3 I/O Board PinoutsRefer to Figure 5.4 for the reverse (solder side) of connector J4 and Figure 5.5 forconnector J3 on the I/O printed circuit board.

FIG. 5.4J4 PINOUTS



FIG. 5.5J5 PINOUTS

5.5.4 Load Cell Calibration ProblemsVerify that the load cell input is changing when the calibration weight is placed on bothsides of the calibration arm. Follow the flow chart to MONITR, PAUTRQ.

If no change, refer to the previuos Torque Troubleshooting procedure.

Verify that the calibration weight value is set to your cal. weight in CALVAL.

Calibrate the load cell and verify that the feedback equals approximately 215 ft/lbs.

5.5.5 PAU Voltage Calibration

Follow the flow chart to CALPRC, scroll to ZR KB1, press ENTER. Verify that the PAUoutput across A+ and A- is 0 vdc but will increase when the MIN pot on the KB board isrotated clockwise.

Go to CALPRC, scroll to HSPKB1, press ENTER. Verify that the PAU output across A+and A- is 30 vdc, if not adjust the IR pot on the KB card until you read 30 vdc.

If you cannot achieve these results, verify that you have approx. 15 vdc across ICom andIPwr on the P4 connector of the I/O board. If this is present, proceed to the next step. Ifthis voltage is not present replace the KB card and recalibrate.

While in a span condition look for approx. 4-6 vdc across ICom and ISig on the P4connector on the I/O board. If not present look for approx. 0.125 vdc across pin 40 (PAUSignal) and pin 1 (Gnd) of the J2 connector on the I/O board.

If this voltage is present here, replace the I/O board and recalibrate.

If this voltage is not present, replace the DAQ-PC and recalibrate.


CONTENTS


6.2 Initial Start 6-2

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Operational Checkout Section6

6-2

6.1 Introduction

After the dynamometer has been installed according to the instructions presented inSection 4 - Installation, you should perform the operational checkout procedure given inthis section to verify that the dynamometer is operating properly.

6.2 Initial Start

1. Be sure system is installed correctly as described in this manual.

2. Turn system ON with all components properly connected and linked to thecomputer. The system should boot up to the customer’s main menu screen.

WARNING: DO NOT DO ANY ADDITIONAL FUNCTIONS with the computer, stayin the main menu screen.

3. Verify the air lines are routed to the proper locations and that the pressure is setbetween 80 - 120 psi. The air supply must be regulated and dried. Turn airsupply on and check for leaks.

WARNING: BE SURE ALL EQUIPMENT AND PERSONNEL ARE CLEAR OFDYNAMOMETER.

4. Activate the lift override switch on the side of the dyne control box. The liftsshould raise and the rolls should lock.

5. Select a "REAR WHEEL DRIVE" vehicle for this Initial Start-up procedure. Checkthe vehicle crank case oil level, radiator level and automatic transmission fluidlevel (if applicable).

6. Ensure the vehicle tires are at their proper road pressure.

7. Be sure that there is no reason that the vehicle should not be operated on thedynamometer. If, for any reason, there are any doubts, DO NOT RUN THEDYNAMOMETER. Instead, please call a Mustang Dynamometer serviceengineer immediately.

8. Drive the vehicle onto the dynamometer. Be sure the vehicle is squared andcentered on the rollers. If the vehicle is not squared and centered, drive off thedynamometer and repeat until the vehicle is squared and centered. Turn vehicle'sengine off.

9. Lower the lifts by turning the override switch on the side of the control box.

10. Start the vehicle, APPLY BRAKE, and put into a forward gear. SLOWLY releasebrake, or clutch if manual transmission, and rotate the tires very slowly (not toexceed 2 mph). After the vehicle is settled, apply brake, put vehicle into park, andturn engine off. This procedure should only take 10-15 seconds.


Operational Checkout


6-3

MD-100 Chassis Dynamometer - Operational Checkout

11. Make sure that the tires are clear of the dynamometer frame.

12. After the vehicle is positioned properly it is MANDATORY to secure the vehiclewith chain binders.

13. Connect exhaust removal system.

14. Position the wheel chocks IN FRONT of the wheels that are not on thedynamometer.

15. The dynamometer is now ready for its first rotational break-in test.

WARNING: The computer should still be in the main menu screen.

16. Be sure all personnel and equipment are clear of the rotating dynamometer andthat no personnel stand in front of the vehicle.

17. Start the engine and apply brake and/or clutch, place the vehicle in its drive gearor a low gear if a manual transmission.

18. Slowly release brake and/or clutch and check to see if the vehicle tires arerotating on the dynamometer. Do not exit your car, check with your assistant.

WARNING: DO NOT ACCELERATE VEHICLE: RUN AT IDLE. BE SURE ALLPERSONNEL ARE CLEAR OF VEHICLE.

19. Run vehicle for 2-3 minutes.

20. Listen for noises, feel and look for vibration. Be sure vehicle does not sway left/right or back /front. Check for any unusual problem.

21. Be sure the driver stays in the vehicle and all personnel stay clear of thedynamometer and of the front of the vehicle.

22. If there are any apparent problems, stop the procedure immediately, apply brakeand stop.

23. If no problem occurs, accelerate vehicle in 10 mph increments up to 50 mph for2-3 minutes at each increment.

24. Repeat steps 22, 23, 24 as required.

25. After running vehicle for 2-3 minutes at 50 mph, slowly apply brake and bring thevehicle to a stop, and put into park.

26. Release and remove all chain binders and move wheel chocks from the vehicle.

27. Activate lift override switch on the side of the interface box. Be sure all personnelare clear. Lift should be raised and rolls should lock.



6-4

28. Be sure exhaust ventilation system is clear. Remove vehicle from dynamometer.

29. Verify and check the torque of all the bolts and set screws to the specificationslocated in the Appendix.

30. IF YOU HAVE ANY QUESTIONS, Please do not hesitate to call our factory at(330) 963-5400.

31. This completes the basic start up rotational test of the equipment.

MD-100 Chassis Dynamometer - Operational Checkout



CONTENTS


7.2 General Information 7-3

7.2.1 Pillow Block Bearings 7-3 (A.) Expansion/Non-Expansion Bearings 7-3 (B.) Locking Bearing to Shaft 7-47.2.2 Gear Tooth Couplings 7-4

7.3 Preventative Maintenance Time Table 7-6

7.4 Lubrication 7-7

7.4.1 General Information 7-77.4.2 Pillow Block Bearings 7-87.4.3 Couplings 7-97.4.4 Power Absorber 7-11

7.5 Inspection & Adjustments 7-12

7.5.1 Check Torque of Bearing Set & Hold Down Screws 7-127.5.2 Check Torque of Coupling Set Screw 7-127.5.3 Check Condition of Coupling Key 7-127.5.4 Check for Roll Lock Brake Pad Wear 7-127.5.5 Check Condition & Tension of Belt 7-13 (A) Condition Check 7-13 (B) Tension Check 7-137.5.6 Power Absorbing Unit Checks 7-13 (A) Check Bearing End Play 7-14 (B) Check Rotor Air Gaps 7-14

7.6 Cleaning & Corrosion Prevention 7-15

7.6.1 Cleaning Your Machine 7-157.6.2 Cleaning The Pit (If Applicable) 7-157.6.3 Corrosion Prevention 7-15

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Preventative Maintenance Section7


LIST OF FIGURES

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7


7-3

MD-100 Chassis Dynamometer - Preventative Maintenance

7.1 Introduction

Proper maintenance procedures performed on a regular basis are essential to the well-being of any machine. By establishing a preventative maintenance program and thenadhering to it you can lower the risk considerably of finding your dynamometer inoperativejust when you need it the most.

This section begins with a general discussion of the following mechanical components ofthe dynamometer:

� Pillow Block Bearings� Gear Tooth Couplings

Later in this section a "Preventative Maintenance Time Table" is presented to give you anidea of the types of maintenance that will need to be performed and the frequency atwhich these activities should be performed. In addition, specific instructions arepresented that provide more detailed maintenance information for various machinecomponents.

7.2 General Information

7.2.1 Pillow Block Bearings

The Dynamometer's rolls, PAU, and inertia weight (optional) are supported by acombination of expansion and non-expansion types of both ball and high capacity doublerow spherical roller bearings

(A) Expansion/Non-Expansion Bearings

During the operation of your dynamometer, temperature changes may cause a linearexpansion or contraction of the various components in the system. In a two pillow blockarrangement (for example on a given roll), at least one non-expansion type of bearing isused as an anchor bearing to accommodate thrust loads and position peripheralequipment. The other pillow block may be of the expansion type to accommodate anyexpansion and contraction in the components. The bearings can be identified as follows:

Expansion-type bearings… are identified by a small white metal diskinstalled under the grease fitting on the bearing'shousing.

Non-expansion bearings… will have either no disk under the fitting or asmall blue metal disk under the fitting.

Preventative Maintenance


7-4


(B) Locking Bearing To Shaft

The inner race of each bearing is securely locked to the shaft on which they are mountedby means of two set screws in the bearing's collar.

7.2.2 Gear Tooth Couplings

Gear Tooth Couplings are used in the drive line of your dynamometer between major sub-assemblies (ex. rolls, PAU, etc.) for the purposes of transmitting torque and enabling thesub-assemblies to be easily removed from the Dyne and allowing for slight offset andangular misalignment as well as end float in drive line components.

Two types of gear tooth couplings are used on Mustang Chassis Dynamometers:

� Hub and Sleeve� Hub and Flange

The performance and life of couplings depend largely upon how you install and maintainthem. Also, the correct installation, alignment, and lubrication of the couplings is critical tothe proper operation of your dynamometer.

If your dynamometer has not been operated for a long period oftime (ex. 5 or 6 months) we strongly suggest that you manuallyrotate the rolls of the dyne for about 10 minutes prior tooperating the unit.

Doing so will enable the bearings to re-establish their self-alignment, thereby minimizing the likelihood of damaging yourmachine when it is operated under power.

CAUTION



7-5

FIG. 7.1HUB & SLEEVEGEAR TOOTHCOUPLING

FIG. 7.2HUB & SLEEVEGEAR TOOTHCOUPLING




7-6

7.3 Preventative Maintenance Time Table

After the dynamometer has been installed according to the instructions presented inSection 4 - Installation, you should perform the operational checkout procedure given inthis section to verify that the dynamometer is operating properly.



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7-7

7.4 Lubrication

7.4.1 GENERAL INFORMATION

Lubrication of the dyne's anti-friction bearings should be done as part of a plannedmaintenance schedule. The recommended lubrication interval given in the "PreventativeMaintenance Time Table" should be used as a guide to establish this schedule.

Mixing lubricants is not recommended due to possible incompatibility. If you desire tochange to other lubricants, follow all of the lubrication instructions provided in this manualand repeat lubrication a second time after 100 hours of service. Care must be taken tolook for signs of incompatibility, such as extreme soupiness visible from grease reliefareas.

A lack of lubricant as well as using the wrong kind will reduce thebearing's life expectancy.Your Mustang Dynamometer was lubricated at the factory usingthe lubricants specified in the chart in the Appendix - "Recom-mended Fluids".We strongly suggest that you continue to maintain your machineusing these same lubricants.

CAUTION

Cleanliness is important in lubrication. Any grease used tolubricate the anti-friction bearings should be fresh and free fromcontamination.Similarly, care should be taken to properly clean all lubricationinlet areas (ex. zerk fittings, fill holes, etc.) to prevent lubricantcontamination.

CAUTION




7-8

7.4.2 Pillow Block Bearing

Refer to the Appendix - "Recommended Fluids" and Fig. 7.3. The frequency at which youshould lubricate the pillow block bearings that was given previously in the PreventativeMaintenance Time Table was based upon an average amount of usage. If you feel thatyour usage is not average, please refer to Table 7.2 to determine a more appropriatelubrication interval.

Using a hand pump grease gun filled with a No. 2 lithium based grease (ex. Mobilith AW2), insert the grease gun into the zerk fitting located either on the lubrication distributionblock (if installed) or near the top of the pillow block bearing. Pump the handle whilerotating the rolls until grease appears at the bearing seals. Remove any excess grease.

High Speed Operation - In the higher speed ranges too muchgrease will cause overheating. The amount of grease thebearing will take for a particular high speed application can onlybe determined by experience. If excess grease in the bearingcauses overheating, it will be necessary to remove the greasefitting to permit excess grease to escape. When establishing arelubrication schedule, note that a small amount of grease atfrequent intervals is preferable to a large amount at infrequentintervals.

It is very important that the pillow block bearings not be over-greased. Over-greasing the bearings can change the parasiticlosses of the dynamometer.

CAUTION

FIG. 7.3PILLOW BLOCK BEAR-ING SET SCREW & LUBEPOINT




7.4.3 Couplings

Refer to the Appendix - "Recommended Fluids" and Fig. 7.4.

Remove a top and bottom plug from one of the coupling hub flanges located on thecircumference of the coupling sleeve (or flange) and then insert a 1/2" NPT zerk fitting intoone of the holes (this can be temporarily removed from one of the bearings). Using ahand pump grease gun filled with a multi-purpose grease, pump the handle until greasecomes out of one of the other holes. Insert a plug in this hole. Repeat this process untilall of the holes are plugged. Then, remove the zerk fitting and then re-install the holeplug. Tighten all the plugs until they are snug - DO NOT OVER-TIGHTEN THE PLUGS.

NOTE: The coupling grease requirements are as follows:Hub & Sleeve style coupling … about 1 ounceHub & Flange style coupling … about 2.5 ounces

The high centrifugal forces encountered in couplings separatethe base oil and thickener of general purpose greases. Heavythickener, which has no lubrication qualities, accumulates in thetooth mesh area of gear couplings resulting in premature meshfailure unless periodic lubrication cycles are maintained.

CAUTION

7-9



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7-10




7.4.4 Power Absorber

Refer to the Appendix - "Recommended Fluids" and Fig. 7.5.

Remove the plug from the relief point on the PAU. Wipe off any dirt or other contaminantsthat may be on the PAU's zerk fitting. Using a hand pump grease gun filled with a lithiumcomplex synthetic grease, insert the nipple into the zerk fitting located on the top of thepower absorber. Pump the handle while rotating the power absorber until grease appearsat the bottom of the power absorber relief point. Remove any excess grease and then re-install the relief plug.

Note: Some PAU's are sealed for life. Thus, they do not have a zerk fitting installedfor lubrication.

FIG. 7.5PAU LUBE & RELIEFPOINTS

7-11




7.5 Inspection & Adjustments

7.5.1 Check Torque of Bearing Set & Hold Down Screws

Refer to the Appendix - "Torque Specifications" for appropriate torque values.

7.5.2 Check Torque of Coupling Set Screw

Refer to the Appendix - "Torque Specifications" for appropriate torque values.

7.5.3 Check Condition of Coupling Keys

Each coupling hub is prevented from rotating on its shaft by a square key (either 3/8" or 1/2" square). For each coupling, determine if its key is worn by grabbing each of thecorresponding coupled rolls and rotating them in opposite directions. If you observe anexcessive amount of play, the key and/or the coupling hub may need to be replaced.

7.5.4 Check for Roll Lock Brake Pad Wear

You can check the roll lock brake pads for signs of wear and deterioration by first loweringthe lift plate and then inspecting the brake pads. If the average brake pad thickness isless than 1/8" or any spot on the pad is less than 1/16" thick, the brake pad will have to bereplaced.

Loctite® 262 has been used on all set screws. If you removeany set screws you must re-apply Loctite® 262 prior to re-installing them.

Do not use an excessive amount of Loctite® 262 on a set screw;about 1/2 drop is usually sufficient to lock the set screw.

CAUTION

When performing this inspection, make sure that the air lift willnot be accidentally raised.

After the lift has been lowered, we strongly suggest that you turnoff the supply air to the dynamometer until after you havecompleted the inspection.

WARNING

7-12




7-13

7.5.5 Check Condition & Tension of Belts

(A) Visual Check

Visually inspect the toothed drive belt to ensure that there are no signs of wear, damage,or deterioration.

(B) Tension Check

The tension applied to the belt that connects the rolls should be sufficient to prevent thebelts from "jumping teeth" on the sprockets.

As a rule-of-thumb only, a properly tensioned belt can be rotated approxi-mately 45° whenit is grasped and twisted at a point on the belt which is midway between the two sprockets.

Toothed drive belts (also called synchronous belts) are not tobe tensioned as you would a V-belt or any other belt thatdepends upon friction to transmit the load. They should beinstalled with a snug fit, neither too taut or too loose. Excessivetoothed belt tension can lead to increased belt and bearingwear.

CAUTION

7.5.6 Power Absorbing Unit Checks

When performing this inspection, make sure that the air lift willnot be accidentally raised.

After the lift has been lowered, we strongly suggest that you turnoff the supply air to the dynamometer until after you havecompleted the inspection.

WARNING




7-14

(A) Check Bearing End Play

1. Refer to Fig. 7.6. Measure the air gap between the rotor and a pole shoe with therotor forced away from the pole shoe by means of two pry bars (ex. screw drivers)located 180º away from each other and 90º away from the pole shoe beingchecked. Measure the gap with a feeler gauge.

2. Measure the air gap between the same rotor and the same pole shoe, but withthe rotor moved towards the pole shoe by two pry bars (ex. screw drivers)inserted in the air gap on the other side of the power absorber. Do not rotate therotor when making the above two checks. Place a chalk mark on the pole shoe toprevent accidental rotating of the rotor.

3. The difference between the above two readings is the bearing end play. Thisvalue should not exceed 0.005". If the bearing end play exceeds 0.005" contactthe factory for adjusting instructions.

(B) Check Rotor Air Gaps

1. Refer to Fig. 7.6. Using feeler gauges, measure and average all eight (8) air gapson each side of the power absorber. The average air gap measurement per sideshould be between .041" and .045".

2. If the average air gap is out of range, contact a Mustang Dynamometer ServiceRepresentative for adjustment instructions.

FIG. 7.6PAU CHECKINGNOMENCLATURE




7-15

7.6 Cleaning & Corrosion Prevention

7.6.1 Cleaning Your Machine

When cleaning your machine you should only use a cloth that has been lightly wetted witheither water or a mild grease/oil/tar remover. After cleaning bright metal parts be sure toapply a coating of corrosion preven-tative. For more information, please refer to theAppendix, "Recommended Fluids".

7.6.2 Cleaning The Pit (If Applicable)

The pit in which your dynamometer has been installed should be cleaned of all foreignobjects and debris. A small paint scraper can be used to loosen any of the built-up dirt; a"shop vac" can be used to pick up any of the smaller debris. Any excessive grease thatmay have been thrown from moving parts should be wiped clean. Also make sure thedrains are clear to avoid water from collecting and causing corrosion.

7.6.3 Corrosion Prevention

Refer to the Appendix - "Recommended Fluids".

After cleaning your machine, be sure to use an anti-corrosive spray on all exposed baremetal to prevent rusting or other forms of corrosion from damaging it.

You should never use pressurized water or compressed air toclean your machine since doing so may force contaminantsinto the machine's bearings.

CAUTION

Special attention should be paid to the air bags and the areassurrounding them since a built-up dirt here could cause wearwhich, in turn, could lead to premature air bag failure.

CAUTION



CONTENTS


8.2 Troubleshooting Guide 8-3

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

SectionSection Troubleshooting8


8.1 Introduction

This section of the manual presents information and procedures that will be beneficial toyou if you encounter a problem with your dynamometer.

The "Troubleshooting Guide" is provided to help you quickly diagnose and correctproblems of a general nature that may arise.

If you encounter a problem with your dynamometer, please don't panic. Quite often"problems" are the result of something very minor such as forgetting to apply air pressureto the dyne or cables that are not connected. When you begin troubleshooting, ifappropriate to the problem being observed, check the obvious first. If this does notcorrect the problem for you, then consult the information presented in this section of themanual. If you are still unable to correct the problem and you have exhausted allpossibilities, please feel free to contact a Mustang Service Engineer.

8-2

MD-100 Chassis Dynamometer - Troubleshooting

Troubleshooting


8-3


8.2 Troubleshooting Guide

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sidnagniraebnonupssahlloR.nrow

.ecnalabfotuosilloR

ecnalabfotuosithgiewaitrenI

thgiewaitreninoeruliafgniraeBylbmessa

emarfretemomanydnostlobrohcnakcehC.snoitacificepsreporpotnethgitdna

ecalpnierasmihserusebdnaenydleveL.dedeenerehwemarfrednu

yrotcafotgnidroccangila-erroriapeR.snoitcurtsni

yrotcafotgnidroccagnilpuocecalpeR.snoitcurtsni

.snoitacificepsreporpotstlobnethgiT

yrotcafotgnidroccasgniraebecalpeR.snoitcurtsni


sdeenyllamroN.raewroftfahsrellorkcehC.gniraebnoswercstesnethgitrollorwen

ecalpeR.llornosthgiewesoolrofkcehC.ylbmessathgiewaitreni


Troubleshooting


8-4


metsyStfiLriA.II


rewoLotsliaFtfiL "PU"nihctiwsedirrevomroftalP.noitisop

ehtothctiwsyekedirrevOmroftalPnruT.noitisop"NWOD"

esiaRotsliaFtfiL sahretemomanydotylppusriA.nodenrutneebton

.deliafsahliocdionelostfilriA

evlavdetautca-dionelostfilriA.deliafsah

etarepootgniliafylppusrewoP.ylreporp

.derutpursahgabriA

sioreznahtrehtodeepslloR.deyalpsidgnieb

.erusserpriawoL

riaderiwylreporpmiroevitcefeD.hctiwserusserp

.rotcennocroelbacevitcefeD

tsohmorflangiselbanelatigiD.tneserptonsiretupmoc

aotdetaluger,riayrD.ylppusrianonruTotdehsinrufebtsum,ISP08foMUMIXAM

.retemomanydeht

ni9&8sniPssorcaCDV21+rofkcehCdionelosecalper,yrassecenfI.tinUlort-noC

.lioc

.evlavecalpeR

dnatinulortnocnisnoitcennoclla)a(kcehCriaper,yrassecenfI.elbacevlavdionelos)b(

.tnenopmocevitcefedecalperro

.gabriaecalpeR

.gniriwdnarosnesdeepstoohselbuorT

otdehsinruferusserpriadetaluger,yrdtsujdA.ISP08foMUMIXAMaotretemomanyd

dnagninepotsetdnagniriwtcerrocyfireV.stcatnochctiwserusserpfognisolc

ynaecalperdnagniriwlacirtcelellatcepsnI.srotcennocro/dnaselbacevitcefed

toohselbuorT.metsyserawtfostoohselbuorT.tinUlortnoCretemomanyD

kcoLtoNoDslloR .nrowerasdapekarB

.metsyscitamuenpnikaelriA

stnioptoviptfilriatasniP.gnissim

.erusserpriawoL

.sdapekarbecalpeR

,gnibutevitcefedynaecalperdnatcepsnI.sgabriaro/dna,srotcennoc

.spilcnipriahdnasnipgnissimecalpeR

otdehsinruferusserpriadetaluger,yrdtsujdA.ISP08foMUMIXAMaotretemomanyd


Troubleshooting


8-5


Troubleshooting


smelborPlanoitarepO.III


toNseulaVyalpsiD,gnitaolF,.e.i(elbatS

).cte,gnitautculF

noitcennocecafretniesooL

noitcennocllecdaoldaB

erasrotcennocelbacllatahterusekaMsnoitcennocllatahtyfireV.detaesylreporp

.eruceseraxobnoitcnujehtedisni

llecdaolllariaper,yrassecenfi,dnakcehC.snoitcennoc

tuodaeRdeepSoN .noitcennoclacirtceledaB

otpukciPcitengaMtcerrocnI.pagriaraeg

.eruliafpukciPcitengaM

ehtnisnoitcennoclacirtcelellakcehC.metsys

."020.ottessipagriatahtyfireV

.pukciPcitengaMecalpeR

CONTENTS

Appendix A - Torque Specifications

Appendix B - Recommended Fluids

Appendix C - Anchor Pod Installation - New Floors

Appendix SectionAppendices Section7

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Documents

CHASSIS DYNAMOMETER Maintenance & Service … Chassis Dynamometer Maintenance & Service Manual WARNING Unsafe operating practices can lead to potentially dangerous situations when